Dual core pickleball paddle

ABSTRACT

Certain embodiments of the present disclosure describe a paddle that may be used for racquet sports. The paddle includes a handle and a blade portion. The blade portion includes a core layer that is formed from at least two different materials. The density, rigidity, and location of the materials used to form the core layer may be altered to provide the paddle with desired playing characteristics.

FIELD OF THE ENDEAVOR

The present disclosure deals with racquet sports.

BACKGROUND

Pickleball is a racquet sport played with paddles and a perforated plastic ball on a court that is similar to a tennis court. Players hit the ball over a net placed on the ground with the goal of hitting the ball so the opposing player cannot return the shot.

Typically, paddles used in pickleball may be made of metal, wood or composite materials. The construction and the weight characteristics of the paddle can have an effect on how a ball rebounds off of the paddle when a player hits a shot. When a player hits a ball near an edge of the paddle, the result of the shot is different than when the ball is hit near the center of the paddle. Often, when the ball is hit near the edge of the paddle, power on the shot is lost, while more power is generated when the ball is hit near the center of the paddle. Different players may prefer either more power or more control. Therefore, it would be desirable to provide a paddle that is made from different materials to provide a player's desired performance and to compensate for the loss of power on an off-center shot.

SUMMARY

Certain embodiments include a paddle including a core that is made from at least two different material areas. The paddle includes a handle and a blade portion. The core portion of the blade is made from at least two different materials and/or two material areas with different densities.

In some embodiments, the basic paddle shape is cut or otherwise shaped to create the core layer. A portion of the core layer is then removed to form an opening in the core. A piece of second material is shaped to match the opening and assembled into the opening in the core layer. Optionally, paddle covering materials, such as a laminate sheet, are then applied to both sides of the assembled core, typically using adhesive, to form the two playing surfaces.

Using different materials to form the core allows the playing characteristics of the paddle to be engineered as desired. For example, in several embodiments, the material that forms the central area of the core is denser and more rigid than the outer area of the core area. Changing the densities and/or the distribution of mass and density can affect the center of balance and the size and location of the paddle's sweet spot. As the center of balance of the paddle moves away from the geometric center and/or as the density differs, the playing characteristics can be adjusted, for example, to allow a greater playable area while minimizing dead spots and paddle deflection. The central area can be made from a dense material such as Nomex, and the peripheral portions can be made from a less dense and less rigid poly material. In other embodiments, a lighter, less dense material can be in the center.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a paddle.

FIG. 2 is a perspective view of an embodiment of a core of the paddle of FIG. 1.

FIG. 3 is a cross-sectional view of the paddle of FIG. 1.

FIG. 4 is a flow chart for a process of making a paddle.

FIG. 5A is a perspective view of an embodiment of a core of the paddle of FIG. 1.

FIG. 5B is a perspective view of an embodiment of a core of the paddle of FIG. 1.

FIG. 5C is a perspective view of an embodiment of a core of the paddle of FIG. 1.

DESCRIPTION OF PREFERRED EMBODIMENTS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

The present disclosure pertains generally to the field of paddles used for racquet sports such as pickleball and particularly to a paddle made with a core including at least two portions formed of different materials of different densities. In structure, the basic paddle or blade shape is cut or otherwise shaped from a core layer material. In some embodiments, a center portion of the core layer may then be cut out or otherwise removed to form an opening in the core. Other embodiments may have a core portion that is formed with a center portion already missing rather than needing to be cut out. A piece of second material is then shaped to match the opening and assembled into the opening. Paddle covering materials, such as a laminate sheet, may then be applied to both faces of the assembled core, for example using adhesive, to form the two playing surfaces.

The rebound characteristics of a ball hit off a paddle depends on the location at which the ball hits the paddle. Traditional pickleball paddles of a single density have a center of balance that is found near the middle of the blade portion of the paddle. This portion of the paddle is often referred to as the sweet spot. A ball hit near the sweet spot of the paddle has more power than a ball that is hit near the edges of the paddle with the same effort. Therefore, it is often desirable to have a paddle that has a large sweet spot located at the portion of the paddle at which the player is most likely to strike the ball.

The International Federation of Pickleball (IFP) endorses rules of pickleball for tournament play and international competitions. The rules of the IFP include equipment requirements that specify allowable paddle characteristics. A pickleball paddle must be constructed from a relatively rigid, non-compressible material. The hitting surface of the paddle cannot include holes, indentations, textured material, or any feature that applies additional spin to the ball. Rubber, synthetic rubber, sandpaper, moving parts that increase momentum, springs or spring-like material, and flexible membranes or compressive material that creates a trampoline effect are not allowed on the surface of the paddle.

The rigidity and compressibility of a paddle is determined using a deflection test. A common deflection test used to determine the rigidity of a paddle applies a force of 3 kg to the center of the paddle. The distance the paddle deflects due to the 3 kg force is recorded to provide a measurement of the paddle's rigidity. A paddle that has a deflection of 0.005 inches or less in the 3 kg test is considered to meet the IFP rigidity specifications.

In addition to regulating the rigidity of a paddle, the IFP also specifies size requirements. The combined length and width of a paddle cannot exceed 24 inches. These measurements include any additional length or width added by an edge guard or a butt cap added to the end of the handle. There are no restrictions on the weight of the paddle or the thickness of the paddle.

It may be desirable to adjust the density distribution and the center of balance of a paddle to adjust the playing characteristics of the paddle to fit different styles of play, while also staying within the paddle requirements and rules set forth by the IFP. Adjustments made to the density distribution and center of balance of a paddle may alter the size and location of the sweet spot and the rebound characteristics of portions of the paddle. These adjustments may be used, for example, to increase the size and optimize the location of the sweet spot, but also to improve or adjust the characteristics of those areas of the paddle found on the periphery or elsewhere on the paddle blade.

As an example, when a ball is hit off a more rigid material, there will be less rebound energy transferred from the paddle to the ball. Although this more rigid material produces less rebound speed of the ball off of the paddle than a less rigid material, it gives the player greater control of the shot. This more rigid material may be desired near the sweet spot of the paddle where a shot hit at this location will already have sufficient speed enabling it to rebound without significant speed or energy loss. In contrast, a lighter, less rigid material may transfer more rebound energy to the ball from the paddle, increasing speed and power at the expense of some of the player's control of where the ball is directed after it is hit. The less rigid material may be desired in peripheral portions of the paddle to increase power, for example in an off-center hit.

Using two materials or areas with different densities allows the playing characteristics of the paddle to be engineered as desired by controlling the density, rigidity, and location of the different materials used. By selectively arranging the locations with different densities, the playing characteristics can be adjusted, for example, to create a larger sweet spot and playable area while minimizing dead spots. As an example, the center portion of the paddle may be made from a dense material with a smaller cell size to improve control while peripheral portions may be made from a less dense material with a larger cellular structure that increases rebound power.

FIG. 1 illustrates an example of a paddle 20 including a handle 30 and a blade portion 40. Typically, a paddle covering 42 is located on each face of a planar blade 40 to form opposing hitting surfaces; however, in other embodiments there may be no paddle covering 42 and the faces are formed by the faces of a core of paddle 20. Paddle coverings 42 may be thin sheets or films of material. Paddle coverings 42 may be made from a non-compressible material, for example, plastic, metal such as aluminum, graphite, cork, fiberglass, a composite material such as an epoxy or carbon fiber in resin, or any other suitable material. Paddle coverings 42 may be the same for both faces of blade 40, or a different covering 42 may be used for each face. The perimeter of blade portion 40 defines a paddle edge 44. In some embodiments, an edge guard (not shown) may be attached around edge 44. Other embodiments may have no edge guard.

Handle 30 is attached to and extends from blade 40. Handle 30 may be integral with blade 40, or alternatively, handle 30 can be separate from blade 40 and attached during assembly. Although handle 30 extends from blade 40, the width and thickness of handle 30 may differ from the width and thickness of blade 40. Handle 30 is sized to allow a user to grip and use paddle 20 comfortably using one hand, so typically, handle 30 is sized to have a smaller width than blade 40 but a greater thickness. Handle 30 may be made from the same material as blade 40, or may be made from a different material. Handle 30 may be designed from a soft material or a harder material, and may include ridges or another form of texture to make handle 30 easier to grip. In some embodiments, a wrap or a grip may surround handle 30 to make holding the paddle more comfortable and/or to enhance paddle control.

As shown in FIGS. 2-3, blade portion 40 includes a planar core layer 50. Typically, yet optionally, paddle coverings 42 are layered on both sides of planar core layer 50 (see FIG. 3). A planar cross-section of planar core layer 50 is constructed of at least two material areas, for example, an outer portion 52 and a central portion 54. The two portions are made of different materials that may be chosen for specific characteristics that affect the playing characteristics of the paddle 20. For example, the different rigidities and densities of the material used for outer portion 52 and central portion 54 may provide different speed or control characteristics when a ball is hit. In some embodiments, the different materials may be the same base material, but have different density characteristics. For example, the two material areas may both be made from polypropylene, but the respective polypropylenes used for the material areas have different densities. In some embodiments, the materials used for the material areas of planar core 50 may have a honeycomb structure or may be made from an open or closed cellular material.

As an example, in one embodiment of paddle 20, outer portion 52 may be made from a comparatively lighter, less dense material, such as polypropylene or polyethylene, and central portion 54 may be made from a comparatively denser, more rigid material, such as Nomex or aluminum. Although outer portion 52 is made of a less dense material than central portion 54, the less dense material of outer portion 52 should be chosen so that the rigidity of paddle 20 conforms with the allowable rigidity maintained by the IFP.

Because the sweet spot of the paddle is most often found near the center of the paddle rather than the edges, in some embodiments, it may be desired that the material used for outer portion 52 is less dense and less rigid than the material used for central portion 54 to provide extra power when the ball is struck near the edge 44 of paddle 20. The extra power provided by the less rigid material used for outer portion 52 is not as necessary when a ball is hit near the sweet spot of paddle 20 located in central portion 54. Therefore, it may be desired to use a denser, more rigid material in central portion 54 to provide greater control of the shot. However, if a player strikes the ball near the edge of paddle 20, a less dense and less rigid material may be desired for outer portion 52 to provide more power to compensate for the loss of power due to not hitting the ball squarely.

A flow chart 100 for a process of making a paddle 20 is shown in FIG. 4. First, a paddle-shaped planar core is formed 110 from a first material area. The planar core includes an edge, a top face, a bottom face, and defines an open area. A second material area is then inserted 120 into the open area. The second material area has a different density than the first material area. Also, the second material area has a planar area that matches the size of the open area. Once inserted into the open area, the second material area is assembled 130 with the first material area to form the planar core. A paddle covering is attached 140 to the top face of the planar core, and then the same paddle covering or a separate paddle covering is attached 150 to the bottom face of the planar core. The planar core extends from a handle. The handle may be integrally formed with the planar core, or may be a separate piece that is attached to the planar core.

In some embodiments, a dual material planar core 50 may be created by first forming the entire core shaped piece from the material used for outer portion 52. Then, the desired shape for the central portion 54 of planar core 50 is removed to create an opening in planar core 50. Removal may be accomplished by routing, cutting, drilling, laser cutting, or any other suitable method. For example, in some embodiments, the middle section may have parallel sides and rounded ends and is in the outer center of the paddle area. The material that is desired to be used for central portion 54 is cut to a shape that matches the opening in planar core 50. This shaped piece is then inserted into the opening to create an assembled core. Central portion 54 is then formed into a completed core with outer portion 52. Several options exist for completing the core with both central portion 54 and outer portion 52. Central portion 54 could be attached using an adhesive, or alternatively, may be molded or bonded to outer portion 52. In some embodiments, central portion 54 may not be physically attached to outer portion 52, but may be held in place using a friction fit or in a floating arrangement between paddle coverings 42, for example, in a sandwich arrangement where paddle coverings 42 are layered on the top and bottom surfaces of planar core 50 and hold the pieces in place together (see FIG. 3).

In other embodiments, the dual material planar core 50 may be created by molding two separate pieces that are then assembled to form a core. For example, outer portion 52 is molded to include an opening positioned at the desired location of central portion 54. Central portion 54 is separately molded in the shape of the opening defined in outer portion 52. Central portion 54 is then secured with outer portion 52, for example, using adhesive, heat bonding, friction fit, a sandwich arrangement, or any other suitable attachment method. Paddle coverings 42 may then be arranged to form top and bottom surfaces over planar core 50.

Alternative arrangements of the different materials used to form planar core 50 are also considered. In some embodiments, a more rigid material may be used in the center of paddle 20. For example, central portion 54 may be formed from polypropylene or polyethylene and outer portion 52 may be made out of aluminum or Nomex.

Also, the shape of the central portion 54 of planar core 50 may be varied. In the embodiments shown in FIG. 2, the central portion 54 of planar core 50 extends with parallel sides from the top edge of planar core 50 to a rounded end near the center of planar core 50. However, as shown with illustrative examples in FIGS. 5A-C, numerous other arrangements are possible. As an example, FIG. 5A shows a planar core 50 with an oval shaped central portion 54 made from one material completely surrounded by outer portion 52 made from a different material. In FIG. 5B, central portion 54 is arranged as a stripe positioned in the center of blade portion 40 and extends the entire length of planar core 50 from a top edge of blade portion 40 to handle 30, and outer portion 52 is attached adjacent to and extending parallel along each side of central portion 54.

Still other arrangements or patterns of different materials to form planar core 50 may be used. In some embodiments there may be more than two different materials used to form planar core 50. As an example, planar core 50 may be made from four different materials including an outer portion 52 and multiple central portions 54, 55, 56 (see FIG. 5C). Although not required, the materials could be arranged to decrease the rigidity of the paddle 20 farther away from the center. In other embodiments, there may be more than one central portion 54. For example, one central portion 54 may be closer to the top edge of planar core 50 and an additional central portion 54 may be found closer to handle 30.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. 

1. A paddle comprising: a handle; a blade portion extending from said handle, said blade portion including a planar core forming a blade defining an area having an edge and two faces, wherein said two faces are separated by a thickness; paddle coverings positioned to cover said two faces of said blade portion; wherein a planar cross-section of said planar core includes at least two material areas selectively arranged within said planar core, and wherein said two material areas have different densities.
 2. The paddle of claim 1, wherein said blade portion is rigid and non-compressible.
 3. The paddle of claim 1, wherein the deflection of the blade portion is 0.005 inches or less when said blade portion is subjected to a force of 3 kg.
 4. The paddle of claim 1, wherein the paddle has a length and a width, and wherein the combined length and width of the paddle does not exceed 24 inches.
 5. The paddle of claim 1, wherein one of said material areas is made from Nomex.
 6. The paddle of claim 5, wherein one of said material areas is made from polyethylene.
 7. The paddle of claim 5, wherein one of said material areas is made from polypropylene.
 8. The paddle of claim 1, wherein said planar core comprises a central portion and an outer portion, and wherein said central portion is made from a material that is more dense than said outer portion.
 9. The paddle of claim 8, wherein a portion of said central portion is arranged adjacent the edge of said blade portion and the rest of said central portion is surrounded by said outer portion.
 10. The paddle of claim 8, wherein the entirety of said central portion is surrounded by said outer portion.
 11. The paddle of claim 8, wherein said central portion is arranged as a stripe positioned in the center of said blade portion and extends along the length from a top edge of said blade portion to said handle; and, wherein said outer portion is formed of two portions positioned adjacent to and extending parallel along each side of said central portion.
 12. The paddle of claim 1, wherein said planar core comprises a central portion and an outer portion, and wherein said central portion is made from a material that is less dense than said outer portion.
 13. The paddle of claim 1, wherein said at least two material areas of said planar core have a honeycomb structure.
 14. The paddle of claim 1, wherein said planar core includes at least three material areas, and wherein each of said at least three material areas has a different density.
 15. A process of making a paddle for a racket sport comprising: forming a paddle shaped planar core from a first material area, wherein said planar core includes an edge, a top face, a bottom face, and defines an open area; inserting a second material area into said open area, wherein said second material area has a planar area matching the size of said open area, and wherein said first material area has a different density than said second material area; assembling said second material area with said first material area to form said planar core; attaching a paddle covering to the top face of said planar core; attaching a paddle covering to the bottom face of said planar core; and, wherein said planar core extends from a handle.
 16. The process of making a paddle of claim 15, wherein said second material area is more dense than said first material area.
 17. The process of making a paddle of claim 15, wherein said second material area is less dense than said first material area.
 18. The process of making a paddle of claim 15, wherein the deflection of the assembled paddle is 0.005 inches or less when the paddle is subjected to a force of 3 kg.
 19. The process of making a paddle of claim 15, wherein the assembled paddle has a length and a width, and wherein the combined length and width of the paddle does not exceed 24 inches.
 20. The process of making a paddle of claim 15, comprising: removing a portion of said planar core to form said open area. 